Regulator valve with integrated direct acting solenoid

Abstract

A control valve for an automatic transmission includes a valve body including a chamber and a control pressure port, metering edges formed in the valve body at the control pressure port, a reference surface formed in the valve body, a spool displaceable along the chamber, and a solenoid module including a pin for displacing the spool, and located in the chamber by contact with the reference surface.

The invention claimed is: 
     
       1. A control valve comprising:
 a cast valve body including an integrally cast chamber and an integrally cast control pressure port; 
 metering edges machined integrally within the valve body at the control pressure port; 
 a reference surface machined integrally within the valve body; 
 a spool displaceable along the chamber; 
 a solenoid module including a pin for displacing the spool, and located in the chamber by contact with the reference surface; 
 wherein the solenoid module includes a first stop surface for limiting movement of the pin in the chamber, and a second stop surface able to contact the reference surface; 
 
       and the spool includes a second land that contacts the second stop surface when the spool moves in the chamber before the pin contacts the first stop surface. 
     
     
       2. The control valve of  claim 1 , wherein the spool is formed with a land that opens and closes communication between the chamber and the control pressure port across the metering edges. 
     
     
       3. The control valve of  claim 1 , further comprising:
 a spring urging the spool against the pin; 
 a second spring urging the pin toward the spool; and 
 a solenoid for producing a magnetic force that opposes a force of the spring and displacing the spool and pin when the solenoid is energized, and allowing the force of the spring to displace the spool and pin when the solenoid is deenergized. 
 
     
     
       4. The control valve of  claim 1 , wherein a first of the metering edges is located on a first side of the control pressure port and a second of the metering edges is located on a side of the control pressure port opposite the first metering edge;
 further comprising a line pressure port communicating a source of line pressure to the chamber, the land opening a connection between the control pressure port and the line pressure port across the first metering edge. 
 
     
     
       5. The control valve of  claim 1 , wherein a first of the metering edges is located on a first side of the control pressure port and a second of the metering edges is located on a side of the control pressure port opposite the first metering edge;
 further comprising an exhaust port communicating a low pressure source to the chamber, the land opening a connection between the exhaust port and the control pressure port across the second metering edge. 
 
     
     
       6. The control valve of  claim 1 , wherein:
 the solenoid module includes an adapter formed with the second stop surface contacting the reference surface. 
 
     
     
       7. The control valve of  claim 6 , wherein:
 the second stop surface is urged into contact with the reference surface by an elastic force produced by a resilient retainer secured to the solenoid module. 
 
     
     
       8. The control valve of  claim 1 , wherein:
 the spool includes consecutive, axially-spaced third and fourth lands, the third land having a cross sectional area less than a cross sectional area of the fourth land, the third land defining a damping chamber in the chamber, a cross sectional area of the damping chamber being greater than a difference between said areas of the third and fourth lands. 
 
     
     
       9. The control valve of  claim 8 , wherein the damping chamber is in hydraulic communication with the control pressure port. 
     
     
       10. A control valve comprising:
 a valve body including a chamber and a control pressure port; 
 metering edges formed in the valve body at the control pressure port; 
 a reference surface formed in the valve body; 
 a spool displaceable along the chamber; 
 a solenoid module including a pin for displacing the spool, and located in the chamber by contact with the reference surface; 
 wherein the solenoid module includes a first stop surface for limiting movement of the pin in the chamber, and a second stop surface able to contact the reference surface; 
 
       and the spool includes a second land that contacts the second stop surface when the spool moves in the chamber before the pin contacts the first stop surface. 
     
     
       11. A control valve comprising:
 a valve body including a chamber and a control pressure port; 
 metering edges formed in the valve body at the control pressure port; 
 a reference surface formed in the valve body; 
 a spool displaceable along the chamber; 
 a solenoid module including a pin for displacing the spool, and located in the chamber by contact with the reference surface; 
 wherein the solenoid module includes a first stop surface for limiting movement of the pin in the chamber, the solenoid module includes an adapter formed with a second stop surface contacting the reference surface, and the spool includes a second land that contacts the second stop surface when the spool moves in the chamber before the pin contacts the first stop surface. 
 
     
     
       12. The control valve of  claim 11 , wherein:
 the second stop surface is urged into contact with the reference surface by an elastic force produced by a resilient retainer secured to the solenoid module. 
 
     
     
       13. A control valve comprising:
 a valve body including a chamber and a control pressure port; 
 metering edges formed in the valve body at the control pressure port; 
 a reference surface formed in the valve body; 
 a spool displaceable along the chamber; 
 a solenoid module including a pin for displacing the spool, and located in the chamber by contact with the reference surface; 
 wherein the spool includes consecutive, axially-spaced third and fourth lands, the third land having a cross sectional area less than a cross sectional area of the fourth land, the third land defining a damping chamber in the chamber, a cross sectional area of the damping chamber being greater than a difference between said areas of the third and fourth lands; and wherein the damping chamber is in hydraulic communication with the control pressure port.